James s



Ahas been made.

Paume! Feb. 1a, 1924.

UNITED STTES PATENT OFFICE.

JAMES S. THOMPSON, OF I ELHAM, NEW YORK.4

BBAKL ASH01", MOLD.

Application le July 220, 1923. Serial No. 652,769.

Shoe Molds. of which the `following is a specification,

T his inventlon relates Yto the manufacture of brake shoes and more partienlarly to the mold in which the shoe is cast. and its object is broadly to enable a brake shoe of approved type with an` integral composite Wearing face to be cast in a permanent mold as well as it can bc east in a sand mold and with theadditioual advantages' of reduction in time and cost.

T0 explain my invention more readily reference may be had to an approved type of car shoe which is standard on a great many railroads at the present time and which has a cast iron body reinforced at the back with a skeleton steel plate em bedded therein and having chilled end portions to provide a com osite wearing face designed to give long li e and requisite friction. The method now employed of making these shoes in green 4sand molds with chill blocks suitably disposed to produce the chilled ends has been common foundry ractice for many years, it is a comparativey slow operation, it. involves much hard and disagreeable Work and the labor cost is considerable. Efforts have been made in the ast to cast brake shoes in permanent mol s providing metal Contact with the casting but, so far as I know, and I have been engaged in the manufacture of brake shoes "for many years, none of these Vcfforts has been commercially successful, notwithstanding the fact that metal molds have been used in making many castings and con siderable development in the general branch of the art of casting in permanent. molds The reason that brake shoes have not been successfully made commercially in permanent molds is because ot' the comparatively large volume of solid metal. the necessity for producing a wearing face ofa predetermined composite character.l and other diiculties which are or will be readily apparent to foundrymcn and manufacturers 4oi' brake'shoes. It may be stated..briey,

`that the metal molds affect the surface of the shoe, producing a change in Athe texture of the body of the shoe, which varies in depth, and generally prevents the production of a shoe having the desired strength and frictionl qualities essential for its service. I am quite sure that the modern standard car shoe of the type above mentioned and having an integral composite wearing face nas never before been cast with eommel-cial success in a metal mold.

Thismodern standard type of car shoe with an integral composite Wearing face havino chilled end portions and an intermediate unchilled soft iron portion or portions has been developed as the resn t of a long period of investigation and tests and commercial use of a great many different ty aesof shoes, and the work has been cariie Von not only by manufacturers of. brake slices and their engineers ,but by and on behalf of the railroads and their engineers, and the roblem has been to produce a shoe ata air cost having the requisite life. strength and friction qualities essentiel for its service under modern conditions. of railroad service. This shoe, which Ihare referred to as an approved type standard on many railroads` is the result of the combined effort of allthose who 'said approved standardty e of brake shoe with a steel' back and chil ed end portions and intermediate soft iron portionor portions. as well as other types of shoes, to be cast satisfactorily on a. commercial scale in a permanent mold, to have all of the desirable qualities of similar shoes made in sand molds and capable of being used interchangeably with Asand mold shoes. y

In the accompanying drawings illustrating .selected embodiments of my invention Fig. 1 is a longitudinal sectional View showing a `metal mold ada ted for making a brake shoe having a steel ack and chilled end portions;

Fig. 2 is a transverse sectional view on the line 9f-2cf Fig. 1;

Fig. 3 is a longitudinal sectional view O l. Figs i's a transverse sectional view on the line 4-4 of Fig. 3.

Referring tothe drawings, 5 represents the cording to conditions of speed and pressure that engineers may be assured of the resultsV which they expect.' The means -em-` uniform and waste avoided. The sand plu permits thegescajpe of gases theretlirougl during ployed forholding'fthelu', the bakedV sand corefand the` reinforcing ack in-place 'are important in'vorder'tl'iat` the shoes may during Vtheca'stingoperationand insures t e production ,of shoes of uniform size, shape "I am aware vthat changes inthe form and constructionand arrangements of parts may be made to. adapt my invention to different sizes, shapes and ty esA of shoes, lu Fan tbacks, and l consi er myself entit ed to makel all such changes as fairly fall within the scope of the invention.

1-. A mold for casting a brake shoe having van integral composite body, and com prising a metal drag'and a metal cope with a brake shoe mold cavity therein, .parts of 4the walls of said cavitybeing bare metal.

of-,said drag and cope' and intermediate parts of the vWalls ofsaid'cavity being com posed 4 a those portions of the shoecastmg .op @site of solid lrefractory material so that v will .the bare metal parts of the cavitywa be chilled and those portionsof the shoe casting oppositethe refractory vparte of the cavity` walls willbe free fromehillingeiect ofthe meta-l drag and cope to produce an v integral shoe body cast-ing composed in part Vof soft cast iron and in part. ofchilled iron.

i 2..A mold' for casting' a brakeV shoe havl ing'an integral compositeA body, and comfractory material.

'prisin a metal drag anda 4metal cope with a brav e s hoc rnold"4 cavity formed' in., said drag androne, the surface fof the "cavity Y "mold cavity, a 'soft sand p Walls in the drag' 'and cope being composed of ,separate 4areas of bare" metal constituting integral parts, of the dragand cope and re- 3. A:v oldfor 'casting a' brake shoe having linxintegral composite. body,` land comprising a metal 4dragand a metal cope with a hrakeshoe mold 4cavity formed in part n the drag and in part, in the. cope, thevsurface of the walls atQthe/ends'of the'. mold cavity being bare metal constituting integral parts of the drag and cope and the surface of the wallsA of the ,moldear/ity between said'bare ends hein composed of refractory material to pro nce a shoe casting with prising a metal drag and a metal co ity.

chilled ends and softA iron intermediate por-y tions.`

, 4`.' "A mold' for'. casting a brake shoe having4 an integral composite body, and com-- i with 'T0 a brake shoejmold cavity therein, t e hot-v ltom wall and one end wall of the mold\ cavity 'being formed in the fdrag, and the to vwall and the -othenend wall of the mold cavity being formed in the cope, por- 76- tions vof said wallsA being bare and other portions havin a refractory facing to produce an integr shoe body casting com in `partof chilled iron and in part o cast iron.

5'.4 Afmold for casting` a brake shoe having anfintegral compositebody, and comprising a metal drag and a metal cope with a. brake shoe moldfcavity therein, the bottom, sides and one 4 end wall of said cavity 4being 7" formed in the drag, and the top and' other` end wall of said cavity being formed in the cope, the end walls in th'e dragoand cope andV adjacent portions of the ttom` and` side walls in the drag being bare to chill the 0" casting, and other portions of the cavity walls havingarefractory facing to prevent chillingvtheoppositely disposed portions of the shoe casting. l

soft

6. A mold vfor casting a brake shoeliavi 9:5 'ing an integral composite body, and eom prlsing a metal drag and a metal cope `with a brakeA shoe lmold cavity therein, sections' of refractory material set/'into the walls of the mold cavity to form a refractory surface in the bottom and side walls of the cav- V intermediatefofits ends and in the top wall of the cavity at its ends to prevent the metal of the drag and cope-from chilling` the shoe casting o posits said refractory A surfaces while the' fare metal of thefdrag andI `cope intermediate 'of said refractory surfaces is permitted to chill the shoe casting to produce an integral shoe body casting composed in` part of soft cast iron jand in' 110 part of chilled iron..l

7. A mold forv casting a brake shoe, and comprising a -metal vdrag` and -a metal cope 4having a in 'old cavity therein, snidfcopehav-z.

inglan opening; communicating with" the lag sans@ "m snafopening, and supporting' means carriedby said plug and projecting into said mold cavityand adapted to be engaged with a .reinforcing back rp. casting to support said back in the" mold cavity during the castingo eration. y

'8.' A m'old forcasting a rake shoe, and comprising a .metal drag and a metal cope having a mold cavity thereinsaid cope havit@ an 'opening communicating' with the rn ld cavity, a soft sand plusr seatedin said opening, aV reinforcing back having Arecessed sides adapted to beembedded in the shoe casting, and supporting megas carried. by

be embedded in. the shoe-12o said plug and engaged with the recessed sides cf the back to support the back in the mold cavity during the casting operation.

9. A mold for casting a brake shoe, and c( mprising a metal drag and a metal cope having a mold cavity therein, said cope having -an opening communicating with the mold cavity, a soft sand plug seat/ed in Said opening, a reinforcing back adapted to be embedded in the shoe casting, and supporting means in said plug projectin into said cavity and adapted to be engage with said back to support the back in the cavity during the casting operation, said supporting means comprising a. looped Wire having its legs extending through the plug in substantially parallel relation, an a transverse supporting bar engaged with the loop and spacing the legs apart.

10. A mold for casting a brake shoe, and comprising a metal drag and a metal cope having a mold cavity therein, said cope hav ing an opening .communicating with the mold cavity, a removable holder adapted to fit in said opening, a soft sand plug carried by said holder, a cross bar engaging the top of the holder, and a looped Wire engaged with said cross bar and projecting' through the plug intothe cavity to support a metal back adapted to beelhhedded in the shoe during the casting operation.

11. A mold for castinga brake shoe, and comprising a mgtal drag and a (metal 'cope having a mold cavity therein, said cope having an opening of 'substantial size extend ing therethrough and cominunicatin with the mold cavity, a. sand plug seated 1n said opening and having a recess adapted to receive the attaching lug and the core for forming the opening in said lug, and means for securing the lug and core 1n the recess in said plug.

12. A mold for casting a brake shoe, and comprising a metal drag and a metalcope having a mold cavity therein, said cope having an opening of substantial. size extending therethrough and communicating with the mold cavity, a sand plug seated in said opening and provided' withA a recess forming a part of the mold cavity 'and -llapted to re ceive the attaching lug and'the oore f or forming the opening therein, and means extending through the plug for securing said lug and core in place.

13. A mold for castingr a brake shoe, and comprising a metal drag and a metal cope having a mold cavity therein, said cope having an opening larger than the attaching lug and the core-for forming the opening therein and communicating* with the mold cavi/ty, a sand plug seated in said opening and having a recess adapted to receive the lug and the core therefor, and means for securing the lug and core in said recess.

14r A mold for casting a brake shoe, and

comprising a metal drag and a metal cope having a mold cavity therein, said cope having an opening extending therethrough and communicating with the mold cavity, a sand plugr seated in said opening and provided with a recess forming a part of the mold cavity, and r'neans for supporting theattaching lug and the core for forming the opening in said lug in said recess.

15. A mold for casting' a brake shoe, and comprising a metal drag` and a metal cope having a, mold cavity therein said cope having an opening extending therethrough and communicating with the mold. cavity, a sand plug seated in said opening, and means embedded in the plug and projecting into the mold cavity for securing in place in the cavity the parts to be embedded in the shoe casting.

16. A mold for casting a brake shoe, and comprising a metal drag, and a metal cope having a mold cavity therein, said cope having an opening extending therethrough and communicating `With the mold cavity, a sand plug seated in said opening, and wires carries by the-plug and projecting into the mold cavity for securing in place in the cavity the parts to be embedded in the shoe casting.

17. A mold for casting a brake shoe, and comprising a metal drag and a metal cope having. a mold cavity therein, said cope having an opening extending therethrough and communicating r a sand plug seated i'n saidopening and forming a part of the top wall of the mold cavity, and means carried. by the plug and projecting into the mold cavity for securing in place in the cavity the parts to be embedded in the` Shoe casting.

18. A mold for castin a brake Shoe haw ing` an integral composlte body, and com prising a metal drag and a metal-cope having a brake shoemold cavity therein, parts of the walls of said cavity being bare metal of said dra. and cope and intermediate parts of t e Walls of said cavity being composed of refractory Hiaterial, so that those portions of the shoe casting opposite the bare metal parts of the cavity walls will be chilled and those por.- tions o f the shoe casting opposite the reractory parts of the cavity Walls will be free from chilling effect of the metal drag and cope to produce an integral shoe body casting composed in part of soft east iron and in part of chilled on, said cope hav- -ing an opening communicating with the mold `cavity,4 and a pl'g in said opening forming a vent for the mold.

19. A mold ,for eastin a brake shoe having an integral composite body, and comprising a metal drag and va metal cope with a brake shoe mold 'cavity therein,. parts of the walls O said cavity being with the mold cavity,"

bare metal of said dra and cope and intermediate parts of t e walls of said cavity being recessed, solid refractory sections fittintgr snugly in said recesses and abutting against the walls thereof to provide `continuous unbroken walls for the mold cavity, whereby those portions of the shoe casting opposite the bare metal parts of the cavity walls will be chilled and those portions of the shoe casting opposite the refractory parts of the cavity walls will be free from chilling effect of the drag and cope to produce an integral shoe body casting composed in part of soft cast iron and in part of chilled iron.

20. A mold for casting a brake shoe havin` an integral composite body, and comprising a metal drag anda metal cope with a brake shoe mold cavity therein,

arts of the walls of said cavity being re metal of said drag and cope'and intermediate Vparts of the -walls of said cavity beiiigrecessed,` Vsolid refractory sections fitting snugly in said recesses and abutting against the walls thereof to provide continuous unbroken walls :for the mold cavity, whereby those portions of the shoe casting opposite the bare metal parte of the cavity walls will he chilled and those portions of the shoe casting opposite the refractory parts of the cavity walls will be free from chilling effect of the drag and cope to produce an integral shoe body casting composed in part of soft cust iron and in part of chilled iron, said cope having an opening: comnnznicating with the mold cavity. und :i plug,r sented in said openini;r and forming a vent for the mold.

21. A mold for rusting' u. bruin: shoe having un integral romposite body, und conipris-ingr a metal drug and n metal cope with n bruke slrocjmold curity therein, parts of the wa'lls of said cavity being bore metal of said drug und cope and intermediate parts of the walls of said cavity being recessed. solid refractory sections fitting snugly in said recesses and abutting),r against the walls thereof to provide continuous unbroken walls for the mold cavity` whereby those portions of the shoe rusting opposite the bore metal parts of the cavity walls will bc chilled und those portions of the shoe costing opposite the refractory pui-ls of thc/cavity walls will be free from chilling effect ol the drag and cope to produce an integral shoe body casting composer] in part of soft cost iron and in part of chilled iron, said co ie hav ing an opening communicatingir with the mold cavity, a plug seated in said opening end forming a vent for the mold, a reinforcing buck adapted to lie embedded in the shoe casting, and supporting means in seid plug projecting into said cavity and adapted to be engaged with said back to support the back in the cnvity during the casting operation,

JAMES S. THOMPSON, 

